Sulfophenoxy malonate compounds

ABSTRACT

Sulfophenoxy malonate compounds and copolyester resins utilizing said malonate compounds comprising the condensation product of (a) an aromatic dicarboxylic acid or its lower alkyl diester, (b) an aliphatic glycol, and (c) a minor amount of a substituted acid or ester thereof represented by the formula:   WHEREIN R1 and R2 are both hydrogen or lower alkyl radicals, R3 is hydrogen or a lower alkyl radical, and M is a metal.

United States Patent Price et al.

[451 Oct.-24, 1972 [54] SULFOPHENOXY MALONATE COMPOUNDS [72] Inventors: John A. Price, 225 North Princeton Avenue, Swarthmore, Pa. 19081; Mary J. Stewart, 2 War-Trophy Lane, Riddlewood, Pa. 19063 221 Filed: Feb. 25, 1971 [21 Appl.No.: 119,013

Related US Application Data [60] Division of Ser. No. 37,838, May 15, 1970, Pat. No. 3,624,034, which is a continuation-in-part of Ser. No. 867,375, Oct. 17, 1969, abandoned.

[52] US. Cl. ..260/470, 260/507 R [51] Int. Cl ..C07c 143/52 [58] Field of Search ..260/470, 521, 507 R [56] References Cited UNITED STATES PATENTS 4/1967 Sakuraiet al ..260/49 1/1972 Bulteau ..260/470 OTHER PUBLICATIONS Kirkiacharian et al., Chem. Abst. 67 82l02e (1967).

Primary Examiner-Lorraine A. Weinberger Assistant Examiner--John F. Terapane Attorney-Thomas R. OMalley, George F. Mueller and Charles A. Haase [57] ABSTRACT Ra mood--ooom wherein R and R are both hydrogen or lower alkyl radicals, R is hydrogen or a lower alkyl radical, and

M is a metal.

4 Claims, N0 Drawings SULFOPHENOXY MAL'ONATE COMPOUNDS This application is a division of application Ser. No. 37,838, filed May 15, 1970, now US. Pat. No. 3,624,034, which in turn is a continuation-in-part of our US. application Ser. No. 867,375, filed Oct. 17, 1969 and now abandoned.

This invention relates to highly polymeric linear copolyester resins which have improved dyeability. More particularly, the present invention relates to novel copolyester resins which can be formed into filaments, films, or other shaped articles and which can be readily dyed with basic type dyes. The term basic dye is used herein to denote cationic organic dyes such as, for example, those containing sulfonium, oxonium, or quaternary ammonium functional groups.

Many types of random copolyesters have been described in the prior art and they can be prepared by various well-known processes. For example, copolyester resins can be prepared by a direct esterification and polycondensation process or by a transesterification and polycondensation process. In the case of the direct esterification method, the reactants used consist of suitable dicarboxylic acids and diols; whereas, in a transesterification method, lower alkyl diesters of suitable dicarboxylic acids and diols are used as the initial reactants.

A copolyester resin, such as those of the present invention, which are suitable for filamentand film-forming purposes should have relatively high intrinsic viscosity, preferably not less than about 0.60 (as determined in a 60 percent phenol-40 percent tetrachloroethane solution, wt./wt., at 30C.), a carboxyl content value of below about 50 equivalents per million grams (eg./l gr. or meg/kg), a suitably high melting point and also exhibit arelatively colorless or white color. Additionally, especially for filament-forming purposes, it is very desirable and necessary in many instances that the polyester resin be dyeable with cationic or basic dyes.

It is an object of this invention to provide novel highly polymeric saturated copolyester resins.

It is another object of this invention to provide highly polymeric linear copolyester resins, which have physical and chemical properties which make them particularly well-suited for filamentand film-forming purposes.

It is a further object of the present invention to provide highly polymeric copolyester resins which are readily dyeable with basic type dyes.

These and other objects are accomplished in accordance with the present invention by providing a highly polymeric copoly-ester resin comprising the condensation polymerization product of (a) an aromatic dicarboxylic acid or its lower alkyl diester, (b) an aliphatic glycol, and (c) a minor amount of a substituted acid or ester thereof represented by the formula:

Rs nlooc-(l z-coolti wherein R and R are both hydrogen or lower alkyl radicals containing from one to four carbon atoms, R is hydrogen or a lower alkyl radical containing from one to six carbon atoms, and M is a metal.

The random copolyester resins of the present invention can be prepared as stated above by either a transesterification or direct esterification process. In

either instances, all the reactants can be initially comwherein z is a positive integer from 2 to 6, R is hydrogen or an alkyl radical having from one to six carbon atoms, M is a metal, A is a divalent saturated aromatic radical, a and b represent positive integers of from i to 3, and R and R represent lower alkyl radicals containing from one to six carbon atoms.

It has been determined that a preferred group of copolyester resins of the present invention are those containing from about 0.5 to 10 mole percent of secondary segments" represented by (2) above and from about 99.5 to mole percent of primary seg-' ments represented by (1) above. Other preferred embodiments contain, in addition to the 0.5 to 10 mole percent of the secondary segments, from 0.5 to 10 mole percent of segments represented by (3) above. Obviously, the copolyester resins of the present invention are not limited by such preferred concentrations. Copolyeste'r resins containing smaller or greater concentrations of segments (2) and (3) above can also be prepared depending on the physical and chemical properties desired along with depth of dyeability needed.

The aliphatic glycols which can be employed in conjunction with the terephthalic acid or diesters thereof used to prepared the primary segments are those having the formula: HO(CH OH, wherein z is a positive integer of from 2 to 6 and cycloaliphatic glycols such as 1,4-cyclohexane dimethanol. Among the a1- kylene glycols that can be used to prepare the primary segments are, for example, ethylene glycol, 1,3- propylene glycol, and 1,6-hexylene glycol.

The saturated aromatic dibasic acid used as the acid component of the primary segments is terephthalic acid. Obviously, if the transesterification method is utilized to prepare the subject copolyesters, a corresponding lower alkyl diester of such a dibasic acid would be used instead of free acid. The alkyl groups of such a dialkyl ester can contain from one to four carbon atoms.

The ester segments (2) above designated secondary segments are derived from an alkylene glycol having the formula: HO'(Cl-l Ol-l, as described above wherein z is from two to six or a cycloaliphatic glycol such as 1,4-cyclohexane dimethanol.

The substituted acid or esters thereof which are used to prepare segments (2) above can be any of those coming within the bounds of the formula:

a mooc-o-ooom A l wherein R and R are both hydrogen or lower alkyl radicals containing from one to four carbon atoms, R is hydrogen or a lower alkyl radical containing from one to six carbon atoms, and M represents any suitable metallic element; preferably, however, because of ease of preparation, M is generally selected from the group consisting of the alkaline earth metals and alkali metals. For example, among the compounds that can be used are the metallic salts of diethyl 2-methyl-2-(psulfophenoxy) malonate, dimethyl 2-(p-sulfophenoxy) malonate, dibutyl 2-propyl-2-(p-sulfophenoxy) malonate, dimethyl 2-penty1-2-(p-sulfophenoxy) malonate, dibutyl 2-hexyl- 2-(p-sulfophenoxy) malonate, or their corresponding dicarboxylic acids and/or suitable mixtures thereof.

Specifically, the above defined sulfophenoxy malonate compounds can be readily prepared from phydroxybenzenesulfonic acid by first titrating same in a water solution with a solution of an alkali metal or alkaline earth metal at room temperature in order to obtain a corresponding dimetallic salt thereof. Then filter the resulting solution and evaporate the obtained filtrate to dryness at reduced pressure. The concentrate obtained is then slurried in acetone and filtered. The precipitate is then dried in vacuo at about to 120C. for three days to yield the corresponding di-metallic salt of p-hydroxybenzenesulfonie acid. For example, the above defined solutions of alkali and alkaline earth metals can be prepared from sodium hydroxide, calcium oxide, lithium hydroxide, potassium hydroxide or barium oxide.

The above-prepared (l) p-hydroxybenzenesulfonic acid, dimetallic salt, and (II) a dialkyl 2-ha1o-2-a1kyl malonate compound at a mole ratio of about 111.2 respectively are placed in a large excess of dimethylformamide and heated at about 90C. for 4 hours, then kept at room temperature overnight. [Alkyl group (1) can contain from one to four carbon atoms, alkyl groups (3) from one to six carbon atoms and halo group. (2) can be chlorine bromine or iodine]. The resulting solution is then evaporated to dryness in vacuo and the concentrate obtained in recrystallized in tants (II) that can be used to prepare the subject sul-- fonated monomers are dimethyl 2-bromo-2-ethylmalonate, dibutyl 2-chloro-2-propyl malonate,

, dimethyl 2-chloro-2-pentylmalonate, dibutyl-2-iodo-2- hexylmalonate, dimethyl 2-bromo-2-methylmalonate, diethyl Z-bromomalonate, dipropyl 2-chloromalonate, dimethyl 2-bromomalonate.

For a more specific illustration, diethyl 2-methyl-2- (p-sulfophenoxy) malonate, sodium salt, can be prepared as follows:

EXAMPLE A (a) A solution of 236 grams (1.0 mole) of a 65v per cent aqueous p-hydroxybenzenesulfonic acid was titrated with a 4N sodium hydroxide solution to a pH of 10.5. The resulting solution was filtered and then evaporated to dryness at reduced pressure. The residue was then slurried in acetone and filtered. The precipitate obtained was dried in vacuo at to C. for three days to yield 236 grams of the disodium salt of p-hydroxybenzenesulfonie acid. (b) A mixture of 54.4 grams (0.25 mole) of p-hydroxybenzenesulfonic acid, disodium salt, and 111 grams (0.3 mole of diethyl 2-bromo-2-methylmalonate in 500 ml. of dry dimethylformamide was heated at about 90C. for about four hours and then kept at room temperature overnight. The resulting solution was evaporated to dryness in vacuo. The residue was then slurried in boiling ethanol and filtered to give a white precipitate on cooling. The resulting compound was identified as diethyl 2-methyl-2-(p-sulfophenoxy) malonate, sodium salt.

The diearboxylic acid counterpart of the above prepared diethyl 2-methyl-2-(p-sulfophenoxy) malonate, sodium salt, is prepared as follows: Take 21.8 grams of diethyl 2-methyl-2-(p-sulfophenoxy) malonate, sodium salt, and mix with a solution of 28 grams of potassium hydroxide dissolved in ml. diethylene glycol. Reflux four hours. Cool to room temperature and acidify to pH 1.0 using dilute hydrochloric acid. The resulting precipitate is then filtered off and dried in vacuo to give 2-methyl-2-(p-sodiumsulfophenoxy) malonic acid.

The ester segments designated (3) above can be prepared from any gem-dialkyl glycol coming within the formula:

wherein a and 12 represent positive integers of from 1 to '3 and R and R represent lower alkyl radicals containing from 1 to 6 carbon atoms. Among those which can be used, for example, are 3,3-dipropyl-l ,S-pentanediol, 2,2-dimethyl-l ,3-propanediol, 2,2-diethyl-l ,3- propanediol, 2,2-dimethyll ,4-butanediol, 3 ,3- dimethyll ,S-pentanediol, 2-ethyl-2-methyl-l ,3- propanediol, and 2,2-dibutyll ,3-propanediol.

Any suitable saturated aromatic dicarboxylic acid known in the polyester art can be used to prepare ester segments (3) above. The term saturated aromatic dicarboxylic acid is used herein to define any aromatic dicarboxylic acid which does not contain any ethylenic unsaturation. Among the dibasic acids which can be used are terephthalic acid, isophthalic acid, 4,4-biben-zoic acid, p,p'-dicarboxydiphenyl propane, 4,4-diphenylsulfone dicarboxylic acid, and 2,6- naphthalene dicarboxylic acid or suitable lower dialkyl esters thereof and any combination thereof.

In the case of the ester-interchange or transesterification method, a mole ratio of diol to suitable diester of from about 1:1 to about 15:1 may be used, but preferably from about 1.5:1 to about 2.6:1. The transesterification reaction is generally carried outat atmospheric pressure in an inert atmosphere such as nitrogen, initially at a temperature range from about 125C. to about 250C., but preferably from about 150C. to 200C. in the presence of a transesterification catalyst. An alkyl alcohol corresponding to the dialkyl ester of the dicarboxylic acid used is evolved and continuously removed by distillation. After a reaction period of l to 2 hours, the temperature of the reaction mixture is raised from about 200C. to about 230C. for approximately 1 to 3 hours in order to complete the reaction, form the desired polyester prepolymer and distill off any excess diol which is present.

Any of the well-known and suitable transesterification or ester-interchange catalysts, for example, lithium amide, lithium hydride, or zinc acetate can be used to catalyze the present transesterification reaction. In most instances, the transesterification catalyst is used in concentrations ranging from 0.01% to about 0.20%

based on the weight of the dialkyl ester of the dicarboxylic acid used in the initial reaction mixture.

Alternatively, the preparation of the subject prepolymers or polyester resins can be achieved via the direct esterification method. In the case of the direct esterification method, a mole ratio of diol to dicarboxylic acid of from about 1.2:] to about .l5:l, but preferably from about 1.511 to about 2.6:] is used. The initial steps of the direct esterification reaction are generally carried out at temperatures ranging from about 180C. to about 280C. in the absence of an oxygen-containing atmosphere at atmos-pheric or elevated pressure for about 2 to 4 hours to form the desired polyester prepolymer. For example, the reaction may be carried out in an atmosphere of nitrogen.

Any of the well-known and suitable first stage direct esterification catalytic additives can be used in the preparation of the present copolyester resins via the direct esterification method. For example, triethylamine or calcium acetate may be used. The first-stage catalystic additives are generally employed at con-centrations ranging from about 5 X mole to about 5 X 10' mole of catalytic additive per mole of dicarboxylic acid used in the initial reaction mixture.

The polycondensation of the prepolymers prepared by one of the above processes is accomplished by adding a suitable polycondensation catalyst to the polyester prepolymer or prepolymers as defined above and heating the blend thereof under reduced pressures -of within the range of about 0.05 mm. to 20 mm. of

mercury while under agitation at a temperature of about 260C. to 325C. for from 2 to 4 hours. Any suitable polycondensation catalyst can be used, for example, antimony oxalate, antimony trioxide, or disodium lead ethylene diamine tetraacetate.

Several preferred embodiments of the resins of the present invention are further illustrated by the following examples.

EXAMPLE 1 One hundred and forty six Grams of dimethyl terephthalate, 9.4 grams of the sodium salt of diethyl 2- methyl-2-(p-sulfophenoxy) malonate, 99 mls. ethylene glycol, and 0.06 grams of lithium hydride was charged into a reaction 'vessel equipped with a nitrogen inlet, a distilling arm, heating means and stirring means. The reaction mixture was agitated and heated at atmospheric pressure to about 198C. under a nitrogen blanket with stirring. The reaction mixture was held at about 198C. for about 2 hours during which time methyl alcohol and other by-products were distilled off. Then the temperature of the reaction mixture was allowed to rise to about 230C. over a period of about 1 hour to distill off any remaining by-products and thereby form the desired copolyester prepolymer. The prepolymer was then allowed to cool under an atmosphere 0 nitrogen.

EXAMPLE [I Fifty grams of the prepolymer product of Example I was mixed with 0.02 grams of antimony trioxide and placed in a reaction vessel. This reaction mixture was then heated at about 280C. under reduced pressure of about 0.1 mm. of mercury while under agitation for about 2 hours to bring about the polycondensation of the prepolymer and formation of a copolyester resin. The copolyester resin product formed had an intrinsic viscosity of 0.61, a diethylene glycol content of 0.93 weight percent, a carboxyl content value of 14 meg/kg, and a Y (C.I.E.) color value of 59.5.

For illustration purposes, the dyeability of the copolyester resin products prepared in the above exam ples were tested with cationic or basic type dyestuffs. The numerical values given below under the name Cationic Dye Value were obtained by measuring the reflectance of the dyed resin with a Color-Eye (Model D-l) which is the trade name for a differential colorimeter manufactured by the Instrument Development Laboratories, Attleboro, Mass. The color values obtained are based on luminance (Y in the C.I.E. System) which is a measure of the proportion of the incidence light reflected relative to a white vitrolite standard and, therefore, a measure of the whiteness of the copolyester resin product being evaluated. Based on a theoretically possible Y value of 100, the higher the Y value, the whiter the resin product. correspondingly, the lower the Y value or number, the more deep or intense the color of the dyed resin product. The determination of Y in the CH5. System as set forth in the examples and hereinafter set forth was carried out by using molded plaques of the polyester resin product having the dimension 1 X1 l/l6 inch which were prepared on a Carver Press.

The prepared molded plaques of the polyester resin samples to be evaluated for dyeability were then subjected to the following dyeingprocedures.

Cationic Dye Test A dye bath was prepared containing 1.25 g. Sevron Blue ER, 10 g. Carolid 3F carrier, 12.5 g. Na SO and 225 mls. water. This bath was heated to 120F. and the samples entered. The bath containing the samples was raised to a boil over a 30 minute period and held at a boil for another 60 minutes. Two scour baths were prepared containing 6.25 mls. of a 1 percent Igepon T-5l Solution, 3.1 mls. of a 1% Na,CO solution, and 240 mls. water respectively. The samples were scoured in these baths at 140F. for minutes each and then air dried.

The copolyester resin product of Example [I above when dyed according to the above-described cationic dyeing procedure had a cationic dye value or Y value of 9.7. A polyethylene terephthalate homoprepolymer prepared with the same catalyst system and under the same conditions as Example II had a cationic dye value or Y value of 17.5.

Other copolyester resins are prepared from dimethyl terephthalate, ethylene glycol, and a minor amount of dibutyl 2-hexyl-2-(p-sulfophenoxy) malonate, sodium salt, and in another instance, a minor amount of dibutyl 2-propyl-2-(p-sulfophenoxy) malonate, sodium salt, by the same procedure as set forth above in Examples l and ll and the resulting copolyester resin products exhibit excellent cationic dye affinity.

Fibers were spun from the copolyester resin product of Example ll and resulting fiber showed excellent dye affinity and retainability.

wherein R and R are both hydrogen or lower alkyl radicals containing from one to four carbon atoms, R;, is hydrogen or a lower alkyl radical containing from one to six carbon atoms and M is an alkali metal.

2. A composition of claim 1 which is diethyl 2- methyl-2-(p-sulfophenoxy) malonate, sodium salt.

3. A composition of claim 1 which is dimethyl 2- ethyl-2-(p-sulfophenoxy) malonate, lithium salt.

4. A composition of claim 1 which is 2-methyl-2-(psodiumsulfophenoxy) malonic acid.

Notice of Adverse Decision in Interference In Interference No. 99,086, involving Patent No. 3,700,721, J. A. Price and M. J. Stewart, SULFOPHENOXY MALONATE COMPOUNDS, final judgment adverse to the patentees was rendered Sept. 9, 1976, as to claim 1.

[Ojficial Gazette February 1, 1 977.]

Po-ww UNITEDYSTATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3 Dated October 24, 1972 Inventor(s) Jo n A. Price and' Mary' Stewart 'It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Abstract page, add: (73) Assignee; FMC Corporation, Philadelphia, Pa. Col. 1, line 35, "eg. should .rea'd -...eq..--; "meg. should read meq. line 53, 'fcopolye'ester." should read copolyester Col. .2, line 8, "instances should read instance line 9, "instan'ce,.'..' should read intc line 43 delete line 44, before "secondary" insert quotation marks. Col. 3, line 58, "dialkyl 2halo-2-alkyl" should read I (3) g 7 dialkyl 2-halo2-alkyl line 68, ,"in" should read is Col. 5, line 13 "biben-zoic" should readbibenzoic line 53, "atmos-pheric" should read atmospheric line 62 "catalystic" should read --caca1ytic line 163 con-centrations" should read e: concentrations Col. 6 line 15 "Grams" should read grams line 46, "meg. should read meq.- Col. 7', line 1, '"l xl xl/l6 inch" should read l"xl"xl/l6" line 6, underline Cationic Dye Test Y Signed and sealed this lst day of 1973.

.-..iJ'-L.LRD FLETCHER, JR. ROBERT GOTTSCHALK attesting Officer Commissioner of Patents 

2. A composition of claim 1 which is diethyl 2-methyl-2-(p-sulfophenoxy) malonate, sodium salt.
 3. A composition of claim 1 which is dimethyl 2-ethyl-2-(p-sulfophenoxy) malonate, lithium salt.
 4. A composition of claim 1 which is 2-methyl-2-(p-sodiumsulfophenoxy) malonic acid. 